The smart-slab’s complex shape is a result of its supporting structure, which was also designed to test new construction methods. It rests on a curved,
12 centimetre thick “mesh mould wall” made using ETH’s In-Situ Fabricator.

Together, these experimental technologies are being combined in order to erect a number of structures. Researchers will then start monitoring and inspecting
the buildings and their components’ performance and durability over time.

Above: A complete 3D printed mould for one of the ceiling segments (image courtesy of ETH Zurich / Andrei Jipa).

Smart slab was developed for the Dfab House and is one of the components seeking to demonstrate how digital design and fabrication can create efficient
structures.

The Smart Slab is just 20 millimetres thick at its thinnest points, and weighs half as much as a conventional ceiling slab.

Once fully assembled, the moulds were coated with oil-based release agents and sprayed with fibre reinforced concrete.

The second step consisted of adding an additional formwork (which was laser was cut from plywood sheets) to create the ceiling's beam structure. The beams
were also pre-tensioned to increase their load bearing capacity.

Above and below: The smart slab ceiling segments being lifted into place (image courtesy of ETH Zurich / Tom Mundy)
and the spatial timber assemblies frame being lifted into position on top of the smart slab ceiling (image courtesy of ETH Zurich / Micheal Lyrenmann).

Once the engineers and construction workers assembled the smart slab ceiling, a timber structure, made using spatial timber assemblies robotic prefabrication process was placed on top.